Collator

ABSTRACT

A collator wherein an inertial roller projects successive sheets toward a gate, and the roller support intercepts sheets that may bounce back; idlers adjustable with respect to feed rollers; a paper deflector imparting a concave aspect to sheets moving onto a stacking table; and idlers larger than driven rollers in juxtaposition peripherally with adjacent idlers.

United States Patent Thomas 1451 June 13, 1972 [54] COLLATOR 3,173,680 3/1965 Dezoppy ..270/58 3,514,095 5/1970 Hot! ..270/58 [721 Wayne. 3,580,563 5/1971 Bassett .....270/53 73] Assi nee: General Blndln Corporation I 8 Northbrook 1 g Primary Examiner-Lawrence Charles Attorney-Popper, Bain, Bobis & Gilfillan [22] Flled: Sept. 23, 1970 211 Appl. -11; 74,666 1571 ABSTRACT A collator wherein an inertial roller projects successive sheets 52 us. c1 .170/53, 271/86 toward a s and the roller pp intercepts Shem that [5]] 1111. C1. ...B65h 39/02, B65h 31/36 may bounce back; idler! adjustabk with respect w fwd [58] Field of Search... ..270/58-60, 4s. a paper impwina a concave aspect 10 sheets 270 52 moving onto a stacking table; and idlers larger than driven rol- 1ers in juxtaposition peripherally with adjacent idlers. [56] References Cited UNlTED STATES PATENTS 8 Clalrm, 6 Drawing figures 2,919,917 1/1960 Worswick ..270/58 X COLLATOR BACKGROUND OF INVENTION 1. Field of Invention This invention relates generally to collators and specifically to collators devised to insure completeness of collation, and exact registration of sheets in each collated set.

2. Prior Art Collators are subject to producing incomplete sets, and failing to stack sheets of each collated set in exact registration. No adjustments are provided to accommodate stacks of sheets of varying heights, or different weights of paper, or different limpness, stiffness, or thickness of paper. The design of known collators is such that sheets often deviate from a preselected course, and are not included in a collated set, or are out of stacked registration.

SUMMARY It has been found that a collator provided with idlers larger than driven rollers, paper deflectors or guides that impart an arch to the sheets, an inertial roller to speed the sheets toward a stop-gate, and an abutment to prevent bounce-back of sheets, will produce uniform stacks of collated sheets in exact registration with each other, and will not omit sheets from a collated group.

DRAWINGS These objects and advantages as well as other objects and advantages may be attained by the device shown by way of illustration in the drawings in which:

H6. 1 is a side elevational view of the collator;

F IG. 2 is a plan view showing the drives;

FIG. 3 is a partial side elevational view showing the discharge end of the collator;

F IG. 4 is a partial top plan view of the collator; and

FIG. 5 is a vertical sectional view taken on the line 5-5, in FIG. 4, looking in the direction of the arrows;

FIG. 6 is a partial side elevational view showing the opposite end of the collator;

PREFERRED EMBODIMENT The collator provides a plurality of trays ll directed obliquely upwardly, each tray holding a plurality of sheets l2. In FIG. 1 only four trays are shown, but numerous others may be supplied. Ejection feet 13 (see US. Pat. No. 2,844,370 W.E.Thomas 7/22/58) move in each tray to expel the top sheet 12 of the stack of papers in each tray. The upper end of the top sheet 12 is projected over a driven, serrated-surface roller 14. A rubber-surfaced idler l5, seated in a slot 16, bears upon the serrated roller 14. The sheets 12 are seized in the nip of the roller 14 and idler l5 and are carried forward horizontally in sequence over successive serrated rollers 14 until they leave the last roller 14. A pair of rubber belts l7 carry the sheets 12 from the last roller 14 downwardly into a collection tray 18 where they are stopped by a gate 19. A pivotably mounted, gravitationally operated paper deflector 20 is positioned over the collection tray 18 and has a pair rollers 21 at the end thereof which ride on the belts 17. immediately preceded by the rollers 21, is a gate 19, which is intermittently raised to collect the sheets 12 as they leave the last driven roller 14 and ride on the belts l7 downwardly toward the gate 19. A straight wire paper deflector 22, also gravitationally operated, hangs over thecollection tray 18 from an axle 29 of the last idler 15. Since the sheets 12, in moving into the collection tray 18, hit the gate 19, and may bounce back, and since at other times, there are some stragglers among the sheets 12, so that the collated group of papers may not be in precise edge-to-edge registration with each other, a speed or jog-roller 23 is provided with a mounting 24 in spaced relation to the gate 19. The sheets 12 will precisely fit the space between the mounting 24 of the jog-roller 23 and the gate 19. As the first sheet 12 moves over the undriven speed or jog-roller 23, it

causes the roller 23 to spin. Successive sheets 12 which encounter this jog-roller, 23 afier the roller 23 has been cleared by the preceding sheet 12, are urged forward by the speed roller 23 into contact with the gate 19 as the roller continues to be spun by each preceding sheet 12 that moves over the roller 23 in contact with it, thereby urging each successive sheet 12 into abutting relationship with the gate 19. Since the sheets 12 also may display a tendency to bounce back from the gate 19, the mounting 24 of the jog-roller 23, having a generally perpendicular front edge acts as a barrier to prevent the successive sheets from bouncing back from the gate 19.

lmrnediately adjacent to the gate at one side of the stack of papers is a stapler 10, which is operated in timed relation to the arrival of a complete group of sheets 12, to staple them together, whereupon the gate 19 is triggered and the collated stapled group of sheets 12 rides out on the belt 17 over the withdrawn gate 19 and is projected into a stacking tray 25. The timing of the stapling machine 24 and of the gate 19 to staple and release a collated group of sheets 12 is accomplished by an adjustable cam 26 that triggers the discharge gate at timed intervals to permit a collated set of sheets 12 to be stapled and discharged. The cam engages an arm 27, which is connected by two other arms 28,28 to the gate. A spring 9 restores the arms 28 to normal afler each contact by the cam 26. The stapler is operated by an electrical impulse immediately preceding the opening of the gate and it is controlled by an electroswitch engaged by the mechanism which opens the gate.

The superposed, gravitationally operated, rubber-surfaced rollers 15 change the direction of the motion of sheets 12 from obliquely upward to horizontal.

It is well known to drive sheets 12 forwardly in the nip of rollers which change the sheet's direction. It has been found that obliquely mounted dispenser trays II, when stacked heavily with sheets 12, may cause a problem in that the sheets are not unerringly projected accurately into the nip of the drive roller 14 and the idler 15. It has been found that if the idler roller I5 is made with a diameter which is approximately equal to or greater than the distance between the axles 29 of the successive driven rollers 14, the moment of force which expresses the sheets 12 from between the idler l5 and the driven roller 14 will be sufficient to overcome the tendency of the sheets 12 to curl downwardly (either due perhaps to their own inherent limpnes, or due to the force of gravity) and will tend to project the sheets linearly i.e., horizontally into the nip of the next succeeding driven roller 14 and idler 15.

An adjustment is provided so that the axles 29 of the idlers 15 may be moved with respect to the axles 30 of the driven rollers 14. Thus, the axles 29 of the idlers 15 may be moved from an initial position lying in the same vertical plane as the axles 30 of the driven rollers 14, to other positions in respect to the axles 30 of the driven rollers 14. This is accomplished by locating the slots 16 in a longitudinal bar 31 with slots 32. Bolts 33 enable the adjustment of the bar to permit positioning of the slots 16 at various positions of offset with respect to the axles 30. Depending upon the degree of ofiset linearly, the sheets 12 may be projected from the nip of the rollers linearly and horizontally in a direction above horizontal so that the sheets 12 unerringly encounter the successive large idler l5 and enter the nip between the idler and the driven roller 14 which succeeds the first pair of idlers l5 and driven rollers 14. By this means the sheets 12 are never directed below the nip of succeeding rollers. The deflecting force of gravity is overcome, and the normal tendency of the sheet 12 to curl, forwardly around the driven roller 14 is overcome. if the idlers 15 were small and had a diameter substantially identical with the driven rollers 14, control of linear movement of the discharged sheets 12 would be less accurate. With large idler rollers 15, the direction of the discharged sheet may be controlled to compensate for (l) the inherent characteristics of the sheets 12; (2) the speed of operation, (3) the direction of movement of the sheet being collated. Thus, in a collator, con trol of the direction of sheets 12 is provided. It is possible to arrange the idler 15, to overlap successive idler rollers 15 by offsetting each transverse set from each succeeding set (not shown). In addition to providing for linear discharge of sheets 11 into the nip of succeeding roller, the larger the idler 15 the more it is able to accommodate higher stacks of sheets in trays 11. An upwardly projected sheet 12 might miss a small idler roller, and not be guided into the nip of the idler l and the driven roller 14. With the large idler roller 15, the upwardly projected sheets 12, whether from a high stack or a low stack, will unerringly be directed against the large idler l5 and into the nip of the idler l5 and the driven roller 14, at all times insuring collation in complete sets without missing or omitting any individual single sheet by reason of failure of a sheet 12 to enter the nip of the idler l5 and driven roller 14. The use of large idler rollers 15 solves several problems of collation arising from the use of conventional pairs of small driven and small idler rollers having the same general diameter. [n such former constructions, in order to insure the precise linear movement of sheets 12 being collated, it has been the practice to use paper deflectors to insure that the moving sheets 12 do not depart from a predetermined linear course. It also has been the practice to use conveyor belts to restrain the sheets from underneath from wandering from the predetermined desirable linear course. Both of these expedients become superfluous by virtue of the large idler roller. In addition, where belts are used, the sheets 12 are distorted in the areas where they are in contact with the belts so that a uniform straight leading edge of a sheet does not enter the nip of the rollers but rather a non-linear edge encounters one or the other of a driven or idler rollers. This results in the jamming of sheets, delayed delivery or marring of the paper. The idler rollers 15 of large sizes, as herein before set forth, avoid such mischances. The use of fixed governing belts or moving governing belts presents the same disadvantages, and the present large idler wheels 15 overcome the disadvantages of both of these types of conventional paper guides. It is known that fixed or moving deflector belts or fixed paper deflectors cause an abrupt or sharp change of direction of travel of a sheet. This coarse deflection of sheets causes numerous problems as already referred. An additional advantage of large idler wheels is that, when the leading edge of sheet encounters the periphery of a large idler 15, it is gently deflected toward the nip of the idler 15 with the driven roller [4 and there is no abrupt deformation of the sheet to a new course immediately adjacent to the leading edge. A gentle deflection or diversion of the somewhat linear movement of the sheet 12 is accomplished, and it is guided toward the nip without any abrupt deflection, thereby again insuring smooth delivery of the sheet toward the collation tray l8 without marring or defacing the sheet. A still further advantage of large idlers 15 over moving or stationary deflecting belts, and stationary rigid deflectors, is that the idlers are mounted in slots 16 and may be easily lifted therefrom. Thus, in the case of a jamming for any reason, it is simple to lift the idler 16 out by the axles 29 from their mounting slots 16, whereupon free and complete access to the trays H is permitted for the removal of jammed sheets or any other misadventure that may be encountered.

A motor 34 drives a first pulley 35 on a shaft 36. A second pulley 37 operates a belt 38 to drive the first driven roller 39 and in turn drives another belt 40 which operates all of the driven rollers 14. The axle of the last driven roller 14 (see FIG. 3) also drives the belts or conveyor 17 in the collection tray 18. Edge guides 41 to center the sheets 12 are provided adjacent to the belts 17. These belts 17, 17 are supported at the discharge end by a roller 42. ldlers 8 bear on the roller 42.

The axle 36 carries a third pulley 43 that drives a belt 44 connected to a fifth pulley 45 on the shafi 46. A pulley 47 on that shaft, drives another belt 48 to operate another pulley 49 on the shaft 50, on which the cam 26 is mounted. The ejection feet 13 are all pivotably mounted on a reciprocating bar 60. The bar 60 is reciprocated by the motor 34, whereby the ejection feet 13 ride up and down on the sheets 12, to eject them from the trays ll.

The pivotably mounted paper deflector 20 has a special relationship to the speed roller 23, as shown in FIG. 5. The bottom edges 61 of the arms of the deflector 20 are supported by the rollers 21 so that they (the edges 61) extend below the plane defined by the top of the speed roller 23. This causes the sheet 12 to be deflected arcuately downwardly (see FIG. 5); in this manner, the middle of the sheet I2 is engaged by the speed roller 23 and projected toward the gate 19 while the marginal edges of the sheets are deflected toward the belts 17, which they encounter a the leading edge of the sheets nears the gate 19. "l11e combination of the speed roller 23 and the belts 17 are thus caused by the paper deflector 20 to urge the sheets 12 into registration with each other in precisely stacked order against the gate 19. Straggler sheets are avoided-precision stacking is insured.

lclaim:

l. A collator comprising a. means for holding a plurality of sheets,

b. means for ejecting a sheet from the means for holding,

c. a plurality of driven rollers above each means for holding,

d. a plurality of successive idlers in contact with the top of the driven rollers,

e. the point of contact of the idlers and the driven rollers defining a tangential generally horizontal plane,

f. the idlers having a diameter substantially larger than the diameter of the driven rollers,

g. the idlers having a diameter to place them peripherally in juxtaposition to the next successive idler,

h. a stacking table adjacent to the last of the driven rollers,

i. a paper deflector above and converging on the stacking table,

j. a pair of driven conveyor belts traversing the stacking table,

k. rollers on the paper deflector engaged with the conveyor belts,

l. a retractable gate near the outer end of the stacking table normally positioned to intercept sheets on the stacking table,

m. a mounting for a speed roller at the inner end of the stacking table, in spaced relation to the retractable gate, positioned to intercept any sheet bouncing back from the gate,

n. a speed roller mounted for free rotation on the mounting, positioned to be engaged and rotated by sheets moving onto the stacking table toward the gate,

0. The paper deflector comprising a pair of anns spaced apart sufficiently to engage longitudinal edge portions of sheets moving onto the stacking table and to deflect the sheets over the speed roller,

p. means to lower, and raise the gate to release a collated set of sheets to leave the stacking table on the conveyor belts.

2. The device according to claim I in which the means for holding a plurality of sheets comprises a. a plurality of trays directed generally upwardly toward the top of the driven rollers.

3. The device according to claim 1 in which the means for ejecting a sheet from the tray comprises a. an ejection foot,

b. a means to reciprocate the ejection foot over the surface of the top sheet.

4. The device according to claim 1 and a. means to shift the idlers to vary their positions with respect to their points of contact with the driven rollers.

5. The device according to claim 1 in which the means to shift the idlers is a. a housing b. a pair of longitudinal bars c. means to attach the bars to the housing in a plurality of positions d. slots in the bars e. axles on which the idlers are mounted f. the axles positioned in the slots and in peripheral engagement with the driven rollers.

6. A collator comprising a. a plurality of means for holding sheets,

b. means for simultaneously ejecting a sheet from each sheet holding means,

c. a driven feed roller above each tray defining a sheet conveyor,

d. an idler above and in gravitational contact with the top of each feed roller,

e. slotted bars on opposite sides of the idlers,

f. a shaft for each idler received at opposite ends in the slots of the bars,

3. means to hold the bars at any one of a plurality of positions thereby to alter the vertical allignment of the axles of the idlers with respect to the axles of the feed rollers.

7. A collator in accordance with claims 6 in which the feed rollers are provided with latitudinally aerated surfaces, and the idler rollers are provided with a high friction periphery.

8. A collator in accordance with claim 7 in which the idler: each have a diameter greater than the driven roller, and are in peripheral juxtaposition with each adjacent successive idler.

i i t i I 

1. A collator comprising a. means for holding a plurality of sheets, b. means for ejecting a sheet from the means for holding, c. a plurality of driven rollers above each means for holding, d. a plurality of successive idlers in contact with the top of the driven rollers, e. the point of contact of the idlers and the driven rollers defining a tangential generally horizontal plane, f. the idlers having a diameter substantially larger than the diameter of the driven rollers, g. the idlers having a diameter to place them peripherally in juxtaposition to the next successive idler, h. a stacking table adjacent to the last of the driven rollers, i. a paper deflector above and converging on the stacking table, j. a pair of driven conveyor belts traversing the stacking table, k. rollers on the paper deflector engaged with the conveyor belts, l. a retractable gate near the outer end of the stacking table normally positioned to intercept sheets on the stacking table, m. a mounting for a speed roller at the inner end of the stacking table, in spaced relation to the retractable gate, positioned to intercept any sheet bouncing back from the gate, n. a speed roller mounted for free rotation on the mounting, positioned to be engaged and rotated by sheets moving onto the stacking table toward the gate, o. The paper deflector comprising a pair of arms spaced apart sufficiently to engage longitudinal edge portions of sheets moving onto the stacking table and to deflect the sheets over the speed roller, p. means to lower, and raise thE gate to release a collated set of sheets to leave the stacking table on the conveyor belts.
 2. The device according to claim 1 in which the means for holding a plurality of sheets comprises a. a plurality of trays directed generally upwardly toward the top of the driven rollers.
 3. The device according to claim 1 in which the means for ejecting a sheet from the tray comprises a. an ejection foot, b. a means to reciprocate the ejection foot over the surface of the top sheet.
 4. The device according to claim 1 and a. means to shift the idlers to vary their positions with respect to their points of contact with the driven rollers.
 5. The device according to claim 1 in which the means to shift the idlers is a. a housing b. a pair of longitudinal bars c. means to attach the bars to the housing in a plurality of positions d. slots in the bars e. axles on which the idlers are mounted f. the axles positioned in the slots and in peripheral engagement with the driven rollers.
 6. A collator comprising a. a plurality of means for holding sheets, b. means for simultaneously ejecting a sheet from each sheet holding means, c. a driven feed roller above each tray defining a sheet conveyor, d. an idler above and in gravitational contact with the top of each feed roller, e. slotted bars on opposite sides of the idlers, f. a shaft for each idler received at opposite ends in the slots of the bars, g. means to hold the bars at any one of a plurality of positions thereby to alter the vertical allignment of the axles of the idlers with respect to the axles of the feed rollers.
 7. A collator in accordance with claims 6 in which the feed rollers are provided with latitudinally serated surfaces, and the idler rollers are provided with a high friction periphery.
 8. A collator in accordance with claim 7 in which the idlers each have a diameter greater than the driven roller, and are in peripheral juxtaposition with each adjacent successive idler. 